Th i n k powe r , Th i n k HSS

GEAR CUTTING
GEAR CUTTING
BASICS AND GEAR SHAPING
2 The basics of gear cutting
3 Types of gears
4 Types of gears
5 Which HSS for maximum efficiency?
6 Coatings for the best performance
7 The basics of shaper cutting
8 Shaper cutter - Vocabulary
9 Types of shaper cutters
10 Types of shaper cutters and work shapes
BROACHING PROCESS
11 The basics of hobbing
12 Hob - Vocabulary
13 Conventional vs. climb hobbing
14 Examples of hobs
15 Special profiles produced by hobbing
16 Chips produced during hobbing
17 How to monitor wear
18 The basics of shaving
19 Shaving cutter - Vocabulary
1
S
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M
M
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Y
THE BASICS OF GEAR CUTTING
2
Used in gear boxes, transmission systems, etc, gears
are essential components in the mechanical industry.
They can be found in all vehicles such as cars,
trucks, tractors, construction equipment but also in
marine drives, rolling mills, generating stations, etc.
Most gears are cut by a hob or a shaper cutter.
Hobbing is a generating process, wherein the metal
is progressively removed to produce gear teeth.
Generation of a gear profile by the enveloping
cuts of a hob
Examples of profiles of cutter teeth vs. profile
of gear teeth
Gear profile
Gear profile
Cutter profile
Cutter profile
TYPES OF GEARS
3
Straight spur gears Helical gears Internal gears
TYPES OF GEARS
4
Straight bevel gears Conical bevel gears Spiral bevel gears
Hypoid gears Helical gears Worm gears
WHICH HSS FOR MAXIMUM EFFICIENCY ?
5
TOOL MAKERS TIP
Reach the highest
performance
with HSS-PM
Used for hobs and
for shaving cutters
Used for hobs and
shaper cutters
Mainly used for
shaving cutters
High performance
High cutting
speeds
Longer tool life
Suitable for dry
machining
Used for hobs and
for shaper cutters
HSS HSS-E
5%-8% cobalt
HSS-PM
(powder
metallurgy)
HSS-E-PM
with cobalt
(powder
metallurgy)
SUCCESS STORY
Operation High speed dry hobbing of planet gears, module 1.25, flank angle 20,
21 teeth, face width 24 mm
Solution HSS-PM hob with multilayer TiAlN coating
Cutting data v
c
220 m/min, f
a
2.5 mm/rev, t
h
12.4 sec.
Benefits Cutting time reduced by 51%and 38% more pieces
(6444 pieces before resharpening)
Steel
20MoCrS4
COATINGS FOR THE BEST PERFORMANCE
TOOL MAKERS TIP
For maximum
coating efficiency,
prefer a HSS-PM
substrate
6
Conventional, general
purpose coating
Reduces friction
Good abrasion-wear
resistance at low cutting
speed
High abrasion-wear
resistance at low cutting
speed and with plain-oil
lubrication
High performance
coating (v
c
120 m/min)
Prevents the tool from
overheating
Suitable for dry hobbing
and dry shaping
High abrasion-wear
resistance at high
temperature
Reduces friction
Limited temperature
resistance
For dry machining
TiN
Gold
TiCN
Grey-violet
TiAlN
or TiAlCN
Black-violet
MoS
2
or WC-C
Grey-black
THE BASICS OF SHAPER CUTTING
7
A gear shaper cutter is basically a gear with teeth
relieved to provide suitable cutting edges and
clearances. The stroking, together with the related
rotation of the cutter and the workpiece results in a
molding-generation process.
Shaper cutters are used to produce gears and also
racks, cams, latches, ratchets, clutches, etc.
This technology is used when hobbing is not possible
due to accessibility problems.
Gear shaper cutter
Gear
Virtual
gear
SHAPER CUTTER - VOCABULARY
A SHAPER CUTTER
AROUND THE WORLD
French: un outil
pignon
German: ein
Hobelwerkzeug
Italian: stozzatore
Spanish: una
herramienta
para cepillar
8
Addendum Whole depth
Pitch circle
Tip chamfer
Tooth
flank
Chamfer
Datum face
Side relief angle
Radial relief
angle
Downhill side
Uphill side
Face angle
Sharpening angle
Helix angle
Side relief angle on uphill side
Side relief angle on downhill side
Helical gear shaper cutter
Inner face
Counter bore diameter
Pitch circle diameter
Outside diameter
Cutting face
C
o
u
n
t
e
r

b
o
r
e

d
e
p
t
h
W
e
B

t
h
ic
k
n
e
s
s
Face angle
O
A
L
B
o
re
d
ia
m
e
te
r
Dedendum
Tooth space
Right tooth
flank
Left tooth
flank
TYPES OF SHAPER CUTTERS
Disk type shaper cutter Shank type shaper cutter
Disk type helical shaper cutter Deep counterbore type shaper cutter
9
TYPES OF SHAPER CUTTERS AND WORK SHAPES
10
Disk shaper cutter for shoulder gears
Deep counterbore shaper cutter with
recessed nut
Pot shaper cutter for external gears
Shank shaper cutter for small diameter
internal gears
THE BASICS OF HOBBING
DID YOU KNOW?
The hob profile
is the mating
profile of
the gear teeth
11
Throughout the hobbing process, the gear blank and
the hob rotate in continuous coordinated movement.
A linear feed is also applied.
The hob resembles a worm with cutting teeth located
where the flutes intersect the worm.
Hob cutting
Hob cutting action
Hob Axial Feed Gear
Gear
Basic Rack
Hob
Hob
HOB - VOCABULARY
A HOB AROUND
THE WORLD
French: une fraise-
mre
German: ein
Walzfrser
Italian:
un creatore
Spanish: una fresa
madre
12
Cam rise Cutting face
Keyway
Flute
Tooth
Top edge
Lead angle
Length of teeth
Overall length
Thread helix
Right edge
Left edge
Hub
Tip radius
Pitch cylinder
Pitch Pressure angle
Whole depth of cut
Whole depth
Hob addendum
Tip relief modification
Normal section of hob tooth profile
Tooth thickness
Straight
portion
Hub face
Hub length
H
u
b

d
i
a
m
e
t
e
r
P
i
t
c
h

c
i
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c
l
e

d
i
a
m
e
t
e
r
B
o
re
d
ia
m
e
te
r
F
l
u
t
e

d
e
p
t
h
O
u
t
s
i
d
e

d
i
a
m
e
t
e
r
CONVENTIONAL VS. CLIMB HOBBING
13
Conventional cut (or up-hobbing)
Climb cut (or down-hobbing)
Hob tooth
Hob tooth
Gear
Gear
Feed direction
Feed direction
Rotatinal
direction
Rotatinal
direction
EXAMPLES OF HOBS
14
Solid hob
Segmented hob Hob for worm wheels
Hob for ratchet wheels
Hob for roller chain sprockets
SPECIAL PROFILES PRODUCED BY HOBBING
15
CHIPS PRODUCED DURING HOBBING
16
Chip produced
by a roughing tooth
Courtesy of J. Rech
Chip produced
by a finishing tooth
Roughing tooth
Workpiece
Hob
Finishing tooth
HOW TO MONITOR WEAR
17
Types of wear on a hob tooth
Wear development on
a hob
A) Flank wear mark width
VB on an uncoated hob
B) Crater wear
development on a
coated hob
B1) Crater wear in the
tooth tip corners
B2) Fully formed crater
wear
Chipping
Cutting edge rounding
Flank wear (fillet)
Back wear
Crater
wear
B2)
B1)
B)
Section A-B
B
A
A)
V
B
V
B
B
A
THE BASICS OF SHAVING
18
Gear shaving is a finishing operation, taking place after roughing with a hob or a shaper cutter.
Shaving consists in removing small amounts of metal from the working surface of gear teeth and produces fine hair-
like chips.
The process also improves tooth surface finish and eliminates, by means of crown tooth forms, the danger of tooth
end load concentrations. Shaving modifies the tooth profile to reduce gear noise and to increase gears load
capacity, safety and service life.
The cutter has the form of helical gear with serrations in the flanks of the teeth acting as the cutting edges.
Gear
Gear
View A
Gear axis
Vc = Vs sin
Vc
Shaving action speed
Vs
Cutter surface speed
P


C
u
tte
r a
x
is
Live center
A
Drive
Driven
Shaving cutter
Shaving
cutter
T.M
SHAVING CUTTER - VOCABULARY
A SHAVING CUTTER
AROUND THE WORLD
French: un outil de
rasage
German: ein
Schaberad
Italian: sbarbatore
Spanish: una
herramienta
de afeitado
19
O
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t
s
i
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e

d
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P
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c
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c
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d
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B
o
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e

d
i
a
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t
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r
Recess
Keyway
Side face
Serration
Clearance
Pitch
circle
End land
Land
Slot
L
a
n
d

w
i
d
t
h
S
l
o
t

w
i
d
t
h
S
e
r
r
a
t
i
o
n

p
i
t
c
h
Serration depth
E
n
d

l
a
n
d

w
i
d
t
h
Top land
Tooth flank
Cutting
edge
Helix angle
Width